PRODUCTION LINE AND METHOD FOR THE PRODUCTION OF ROD-SHAPED ARTICLES OF THE TOBACCO INDUSTRY

Abstract

 The invention relates to a method for the production of rod-shaped articles of the tobacco industry, each of which is a multi-component article (2) which comprises a plurality of cylindrical segments (3) aligned with each other along the respective longitudinal axes (X); and comprises: making at least some of the segments (3) forming each article (2) in the form of cylindrical capsules (3a), with a diameter equal to the diameter of all the segments (3) and containing inside them a filling material, in particular granules or fibres; feeding the segments (3) to the assembling unit (6), an inlet (I) of which is positioned and shaped to receive, in particular in an orderly succession, the capsules (3a); combining the segments (3) in groups in a modular combination section of the assembling unit (6); and wrapping a wrapping material around the combination of segments (3) in a wrapping section of the assembling unit (6).

Description

[0001] This invention relates to a line and a method for the production of rod-shaped articles of the tobacco industry.

[0002] Hereinafter, the term "rod-shaped articles of the tobacco industry" is used not only to denote conventional cigarettes, which are intended to be smoked following the combustion of tobacco, but also new generation cigarettes, which are intended to be smoked following heating of the tobacco or of an alternative substance capable of producing an aerosol.

[0003] Alternatively, the term "rod-shaped article of the tobacco industry" may also denote the filters used to make what are known as "filter cigarettes". Some examples of production lines that make cigarettes, in particular filter cigarettes, are known from patent documents WO2005/046365, US4321050 and US2006201523.

[0004] The production lines described in the documents just mentioned have a twofold disadvantage. On the one hand, they have a considerably large footprint and, on the other, they have a rigid configuration that does not allow quick and easy changeover: that is to say, changing from the production of cigarettes of one kind to the production of cigarettes of a different kind cannot be carried out rapidly.

[0005] A line for the production of filters, in particular multi-component filters, is known, on the other hand, from patent document EP1787534, again by way of example.

[0006] In this case, too, changeover from the production of filters of one kind to filters of a different kind is neither quick nor easy. That is because changing over from one product to another means supplying filter components from different storage units, which translates as greater complexity in logistic terms and due also to the footprint of the storage units themselves. Generally speaking, manufacturing lines currently available on the market for the production of rod-shaped articles of the tobacco industry are dedicated to the production of cigarettes only or of filters only and, in both cases, are very rigid in production and/or plan configuration terms.

[0007] The aim of this invention is to provide a line and a method for the production of rod-shaped articles of the tobacco industry that are free of the above mentioned disadvantages.

[0008] Provided by this invention are a line and a method for the production of rod-shaped articles of the tobacco industry as set out in the appended claims. The invention is described below with reference to the accompanying drawings, which illustrate a non-limiting embodiment of it and in which:

• Figure 1 schematically represents a line for the production of rod-shaped articles of the tobacco industry according to this invention;
• Figure 2 is a front view of a line for the production of rod-shaped articles of the tobacco industry made according to this invention;
• Figure 3 is an enlarged front view of a portion of the production line of Figure 2; and
• Figure 4 schematically represents a part of the method for the production of rod-shaped articles of the tobacco industry according to this invention.

[0009] With reference to Figure 1, the reference numeral 1 denotes in its entirety a line for the production of rod-shaped articles 2 of the tobacco industry.

[0010] As mentioned above, the term "rod-shaped articles of the tobacco industry" is used to mean either the cigarettes or the filters as specified above.

[0011] The articles 2, be they cigarettes or filters, are of multi-component type, that is to say, they comprise a plurality of cylindrical segments 3 which are aligned with each other along the respective longitudinal axes X and are wrapped together in a tubular wrap 4 of wrapping material. Preferably, the tubular wrap 4 placed round all or part of the set of segments 3 is made of paper.

[0012] The articles 2 may in turn be semi-products to be sent on for further processing, or finished products of the cigarette or filter type.

[0013] The segments 3 making up each article 2 may be in contact with each other, one after the other (as shown in Figure 1) or in one or more pairs of adjacent segments 3, where the segments 3 may be separated by a space.

[0014] More specifically, at least one of the segments 3 is a capsule 3a containing a filling material. The filling material may be a material that produces an aerosol, such as tobacco granules or fibres, or an aromatic material - for example in the form of granules consisting of microcapsules containing an aromatic liquid - or a filter material such as activated carbon granules, cellulose acetate fibres, silica gel granules or a material having a cooling effect while smoking the article 2, such as PLA (polylactic acid) granules or fibres.

[0015] For example, in the case where the articles 2 are multi-component cigarettes, at least one of the capsules 3a may contain tobacco granules or fibres capable of creating an aerosol. In this case, there may be at least one further capsule 3a containing, for example, filter material or PLA granules or fibres.

[0016] Similarly, again by way of example, in the case where the articles 2 are multi-component filters, at least one of the capsules 3a may contain filter material or PLA granules or fibres.

[0017] In the context of this invention, the term "granules" includes what are known as "powders".

[0018] Also in the context of this invention, the segments 3 which are not capsules 3a as specified above may contain tobacco, such as shredded tobacco or a crimped and gathered tobacco sheet, for example, or a filter material such as cellulose acetate, for example.

[0019] The production line 1 comprises a plurality of units 5 for feeding respective segments 3, of which at least one, labelled 5a, is positioned and shaped to supply the aforementioned capsules 3a.

[0020] Advantageously, to make the production line 1 highly versatile and reconfigurable, the feed units 5 are independent of each other; that is to say, they can be substituted, omitted or moved one by one.

[0021] More specifically, the feed unit 5 is positioned and shaped to feed the capsules 3a in an ordered succession.

[0022] The production line 1 also comprises an assembling unit 6, adapted to make up the sets of segments 3 and to wrap them in the tubular wrap 4 of wrapping material to make the multicomponent articles 2.

[0023] Figure 2 illustrates a possible embodiment of this invention, in which the assembling unit 6 is fed by four feed units 5, of which only one, positioned in line with the assembling unit 6, feeds the capsules 3a. The assembling unit, better illustrated in Figure 3, comprises a unit 7 for making the capsules 3a and a transfer conveyor 8, which is interposed between the unit 7 for making the capsules 3a and the assembling unit 6 and which is configured to transfer in sequence the capsules 3a in an ordered succession from a pickup station U, located at the outlet of the unit 7 for making the capsules 3a, to a delivery station I, located at the infeed of the assembling unit 6.

[0024] The unit 7 for making the capsules 3a comprises the following, in succession:

• a station A for feeding empty capsules 3a,
• a station R for filling the capsules 3a, and
• a station C for closing the full capsules 3a.

[0025] Looking in more detail, the station A is configured to receive from an overhead line 9 a plurality of tubular bodies 10, illustrated in Figure 4, from which the cylindrical tubular walls of the capsules 3a are formed by multiple transverse cutting.

[0026] Preferably, the tubular bodies 10 are made of paper material.

[0027] For the purpose, the length of the tubular bodies 10 is a multiple of the length of the capsules 3a. For example, as illustrated in Figure 4, the length of the tubular bodies 10 is eight times the length of the capsules 3a.

[0028] The station A comprises a feed hopper 11 configured to contain the tubular bodies 10 in bulk and to feed them to a train of drums 12 by which the tubular bodies 10 are, in a known manner not described herein, cut into segments whose length is equal to the final length of the capsules 3a and which are then axially offset from each other and then aligned, one after the other, in such a way as to form a succession of segments whose main axis of extension X is perpendicular to the feed direction of the succession. The train of drums 12, fed with a mass of tubular bodies 10, thus delivers to a transfer drum 13 an ordered succession of segments, each defining the cylindrical tubular wall of a capsule 3a.

[0029] The station A also comprises a device 14 for feeding a continuous web N of wrapping material, from which to make by transverse cutting a plurality of connecting strips used to wrap the respective tubular wraps conveyed in succession by the drum 13.

[0030] The web "N" may be a single layer of paper or a multilayer material such as, for example, a metal foil and paper laminate.

[0031] Optionally, the web N may be perforated. In this case, the perforations may be made prior to feeding it (that is at the paper mill) or in-process while it is being unwound by specific perforating means of known type, not illustrated, such as laser devices or mechanical perforators.

[0032] The station A also comprises a gumming device 15 to apply a layer of adhesive on the web N and a cutting device 16 to divide the web N into connecting strips, as described above.

[0033] The station A also comprises a receiving drum 17 configured to receive, from the cutting device 16, the succession of connecting strips and, from the transfer drum 13, the tubular segments used to make the capsules 3a. Next, the drum 17 feeds the connecting strips and the segments to a rolling drum 18 in such a way that each connecting strip is applied in cantilever fashion to a respective tubular segment.

[0034] The rolling drum 18 acts in conjunction with a rolling bed 19 configured to roll each connecting strip around the respective tubular segment.

[0035] Downstream of the rolling bed 19, the station A comprises a device 20 for closing a first of the two longitudinal ends of the capsules 3a. The first longitudinal end, labelled 21 and illustrated in Figure 4, defines the bottom of the capsules 3, ready to be filled at the filling station R.

[0036] The closing device 20 comprises a train of horizontal axis feed drums 22, each equipped with a plurality of closing means (not illustrated) moved by a fixed cam (not illustrated).

[0037] Each closing means comprises a drive rod, slidable in a respective linear guide and engaged with the fixed cam in such a way that during rotation of the feed drum 22, the cam causes the closing means to move with reciprocating translational motion in the direction of the longitudinal axis of the tubular segments with which the capsules 3a are formed.

[0038] In a first embodiment, the closing means fold the ends of the connecting strips that protrude from the edges of the tubular segments on which the connecting strips themselves are wrapped and glued.

[0039] In a further embodiment, the closing means fold the ends of the tubular segments on which the connecting strips themselves are wrapped and glued.

[0040] Folding the connecting strips or the segments or both is preferably carried out in sectors - for example in four sectors - in successive steps along the path defined by the train of feed drums 22. In other words, one sector is folded on each feed drum 22 until all the sectors are folded.

[0041] In a simplified variant, not illustrated, the feed station A may receive and transfer ready-made empty capsules, that is to say, capsules already provided with the bottom, as specified above.

[0042] On leaving the station A, the capsules 3, each provided with the bottom and open at the end opposite the bottom, are picked up by a tapered drum 23, configured to transfer the empty capsules 3a to the filling station R and to modify their orientation from horizontal to vertical with the open end facing up, ready for filling.

[0043] The filling station R is provided with at least one vertical axis feed drum 24 which in turn comprises a fixed cam (not illustrated) and on which a plurality of filling means 25 is mounted. The filling means 25 each comprise a drive rod (not illustrated) which is slidable in a respective linear guide and which is engaged with the fixed cam in such a way that as the feed drum 24 rotates, the cam mechanism causes a reciprocating translational movement of the filling means 25 along a vertical direction, parallel to the main axis of extension of the succession of capsules 3a as they pass through the filling station R.

[0044] The closing station C, located downstream of the filling station R, comprises a device 26 for closing the second of the two longitudinal ends of the capsules 3a. The second longitudinal end, labelled 27 and illustrated in Figure 4, defines the top of the capsules 3a, closed and ready to be conveyed to the assembling unit 6.

[0045] The closing device 26 is the same as the closing device 20 described above, except that the feed drums have a vertical axis instead of a horizontal axis. In particular, the closing device 26 comprises a train of vertical axis feed drums, each equipped with a plurality of closing means (not illustrated) moved by a fixed cam (not illustrated).

[0046] Each closing means comprises a drive rod, slidable in a respective linear guide and engaged with the fixed cam in such a way that during rotation of the feed drum, the cam causes the closing means to move with reciprocating translational motion in the direction of the longitudinal axis of the capsules 3a.

[0047] Downstream of the closing station C there is a tapered drum 28 that is the same as the tapered drum 23 described above.

[0048] The drum 28 is configured to transfer the full capsules 3a from the closing device 26 to the pickup station U of the assembling unit 6 to modify its orientation from vertical to horizontal.

[0049] In the station U, the drum 28 engages the transfer conveyor 8, which comprises at least one transfer drum 29 provided with seats (not illustrated), each adapted to contain a respective capsule 3a. Preferably, the seats for containing and transporting the capsules 3a are connected to a conventional suction source which is not illustrated.

[0050] Preferably, the transfer conveyor 8 comprises a train of transfer drums 29. Preferably, the train 29 of drums is assembled in modules.

[0051] Alternatively, in a variant not illustrated, the transfer conveyor 8 is a linear conveyor: that is to say, it comprises a conveyor belt trained around at least one pair of (horizontal axis) pulleys. In this case, the conveyor belt is provided with seats (not illustrated), each adapted to contain a respective capsule 3a. In this case, too, the seats for containing and transporting the capsules 3a are connected to a conventional suction source which is not illustrated.

[0052] In a further variant, not illustrated, the transfer conveyor 8 comprises a buffer (storage unit) for accumulating the capsules 3a and whose function is to compensate for any differences in production speed between the unit 7 for making the capsules 3a and the assembling unit 6. The buffer is a buffer of conventional type, not described herein, preferably a FIFO (first in first out) buffer.

[0053] Whatever the case, the transfer conveyor 8, whether provided with the buffer or not, ensures that the capsules 3a produced in situ by the unit 7 are transferred directly and in sequence, in an ordered succession. This simplifies the entire production process of the articles 2. In particular, if the capsules 3a have an assembly direction, their bottom-to-top orientation is thus maintained.

[0054] Moreover, the integrity of the capsules 3a is also maintained, since their storage in a mass and subsequent singulation could easily damage the capsules 3a, especially their longitudinal ends, delicately folded during production.

[0055] In a variant not illustrated, the unit 7 for making the capsules 3a is not provided and the transfer conveyor 8 of the unit 5a for feeding the capsules 3a receives the capsules 3a from an overhead feed line or hopper and transfers them to the delivery station I located at the infeed of the assembling unit 6.

[0056] In all the variants described above, the transfer conveyor 8 is configured to pick up the capsules 3a from a first path, along which the capsules 3a advance in a direction transversal to their longitudinal axis, and to deliver the capsules to a second path, along which the capsules 3a advance in a direction transversal to their longitudinal axis.

[0057] Alternatively, in a different embodiment, not illustrated, of the line for the production of the articles 2, the transfer conveyor is configured to pick up the capsules 3a from a first path, along which the capsules advance in a direction transversal to their longitudinal axis, and to deliver the capsules 3a to a second path, along which the capsules 3a advance in the direction of their longitudinal axis.

[0058] As illustrated in Figure 2, the assembling unit 6 comprises a modular section 30 for combining the segments 3 in groups, where each module 31 is fed by at least one respective feed unit 5 and is provided with a plurality of drums 32 for feeding the segments in a direction transversal to their longitudinal axis and in which at least two adjacent modules 31 combine the segments by means of two respective drums 32 operatively coupled to each other.

[0059] Following the section 30, the assembling unit 6 comprises a wrapping section, equipped with a wrapping device 33 for wrapping a wrapping material around the combination of segments.

[0060] More specifically, the module 31 that is fed with the capsules 3a by the transfer conveyor 8 (hence by the feed unit 5a) is simultaneously fed by a further feed unit 5 equipped with a hopper, while each of the remaining modules 31 is fed by a single feed unit 5 equipped with a hopper.

[0061] The wrapping device 33 comprises a rolling unit 34 through which the segments, made up of groups, are wrapped in a sheet of wrapping material, in particular paper, during a rolling motion of the segments themselves about their longitudinal axis.

[0062] The ways the modules 31 and the wrapping section are positioned relative to each other and cooperate with each other are described in detail in patent document WO2014/064655, which is incorporated herein by reference.

[0063] In a variant not illustrated, the wrapping device of the assembling unit comprises a forming beam along which the segments, made up of groups, advance aligned with one another along the respective longitudinal axes and wrapped during their advance by a continuous web of wrapping material, in particular paper, for forming a rod.

[0064] A wrapping device of this kind is described in detail in patent document EP1787534, which is incorporated herein by reference.

[0065] What is described in the foregoing allows making rod-shaped articles of the tobacco industry, be they cigarettes or filters, which comprise a plurality of component segments, at least one of which is a (cylindrical) capsule, in turn comprising a tubular side wall, a closed top end and a closed bottom end and containing inside it a filling material, specifically granules (for example, of tobacco) or fibres (for example, of PLA).

[0066] The method by which the articles 2 are made by the production line 1 comprises the following steps:

• making at least some of the segments 3 forming each article 2 in the form of cylindrical capsules 3a, with a diameter equal to the diameter of all the segments 3 and containing inside them a filling material, in particular granules or fibres;
• feeding the segments 3 to the assembling unit 6, an inlet I of which is positioned and shaped to receive, in particular in an orderly succession, the capsules 3a;
• combining the segments 3 in groups in the modular combination section 30 of the assembling unit 6, in which each module 31 is equipped with a plurality of drums 32 for feeding the segments 3 in a direction transversal to their longitudinal axis (X), and in which at least two adjacent modules 31 combine the segments 3 by means of two respective drums 32 operatively coupled to each other; and lastly
• wrapping a wrapping material around the combination of segments 3 in the wrapping section of the assembling unit 6.

[0067] The step of feeding the capsules 3a to the assembling unit 6 comprises transferring in sequence the capsules 3a in an ordered succession from a pickup station U, located at the outlet of a unit 7 for making the capsules 3a, and a delivery station I, located at the infeed of the assembling unit 6.

[0068] More specifically, the transfer of the capsules 3a comprises picking up the capsules 3a from a first path, along which the capsules 3a advance in a direction transversal to their longitudinal axis X, and delivering the capsules 3a to a second path, along which the capsules 3a advance in a direction transversal to their longitudinal axis X.

[0069] Alternatively, the transfer of the capsules 3a comprises picking up the capsules 3a from a first path, along which the capsules 3a advance in a direction transversal to their longitudinal axis X, and delivering the capsules 3a to a second path, along which the capsules 3a advance in the direction of their longitudinal axis X.

[0070] Lastly, the step of wrapping the wrapping material around the combination of segments 3 (at least one of which is, as already mentioned, is a cylindrical capsule 3a of the same gauge size) is performed in a rolling unit 34 through which the segments 3, made up of groups, are wrapped in a sheet of wrapping material, in particular paper, during a rolling motion of the segments 3 about their longitudinal axis X.

[0071] Alternatively, based on a variant described above, the step of wrapping the wrapping material around the combination of segments 3 is performed in a forming beam along which the segments 3, made up of groups, advance aligned with one another along the respective longitudinal axes X and wrapped during their advance by a continuous web of wrapping material, in particular paper, for forming at least one rod.

[0072] The possibility of filling the capsules, in particular in situ, with different material according to different production requirements, for example with a material that produces an aerosol or, alternatively, with an aromatic, filtering or cooling substance, as specified above, without major alterations to the logistics of the production line, allows making the production line adaptable and versatile and capable of easily and quickly performing production changeovers, even from cigarettes to filters and vice versa.

Claims

1. A production line for rod-shaped articles of the tobacco industry, each of which is a multi-component article (2) which comprises a plurality of cylindrical segments (3, 3a) aligned with each other along the respective longitudinal axes (X), characterized in that it comprises:

- a plurality of units (5, 5a) for feeding respective said segments (3, 3a), of which at least one (5a) positioned and shaped to supply, in particular in an orderly succession, segments (3a) consisting of capsules (3a) containing inside them a filling material, in particular granules or fibres; and

- a unit (6) for assembling said segments (3, 3a), in turn comprising in succession:

- a modular section (30) for combination of the segments (3, 3a) in groups, where each module (31) is fed by at least one feed unit (5, 5a) and is provided with a plurality of drums (32) for feeding the segments (3, 3a) in a direction transversal to their longitudinal axis and in which at least two adjacent modules (31) combine the segments (3, 3a) by means of two respective drums (32) operatively coupled to each other; and

- a wrapping section, equipped with a wrapping device (33) for wrapping a wrapping material around the combination of segments (3, 3a).

2. The production line according to claim 1, wherein the feed units (5, 5a) are independent of each other.

3. The production line according to claim 1 or 2, wherein the unit (5a) for feeding said capsules (3a) comprises:

- a unit (7) for making the capsules (3a), comprising in succession a station (A) for feeding empty capsules (3a); a filling station (R), which is equipped with a plurality of filling means (25) for inserting the filling material in each empty capsule (3a) through a respective open longitudinal end (27); and a closing station (C), which is equipped with a plurality of closing means for making in each full capsule (3a) a respective wall for closing the open longitudinal end (27), said closing wall being transversal to the longitudinal axis (X) of the capsule (3a); and

- a transfer conveyor (8), which is interposed between the unit (7) for making the capsules (3a) and the assembling unit (6) and is configured to transfer in sequence the capsules (3a) in an ordered succession from a pickup station (U), located at the outlet of the unit (7) for making the capsules (3a), to a delivery station (I), located at the infeed of the assembling unit (6).

4. The production line according to claim 3, wherein the transfer conveyor (8) is configured to pick up the capsules (3a) from a first path, along which the capsules (3a) advance in a direction transversal to their longitudinal axis (X), and to deliver the capsules (3a) to a second path, along which the capsules (3a) advance in a direction transversal to their longitudinal axis (X).

5. The production line according to claim 3, wherein the transfer conveyor (8) is configured to pick up the capsules (3a) from a first path, along which the capsules (3a) advance in a direction transversal to their longitudinal axis (X), and to deliver the capsules (3a) to a second path, along which the capsules (3a) advance in the direction of their longitudinal axis (X).

6. The production line according to any one of claims 1 to 5, wherein the wrapping device of the assembling unit (6) comprises a forming beam along which the segments (3, 3a), made up of groups, advance aligned with one another along the respective longitudinal axes (X) and wrapped during their advance by a continuous web of wrapping material, in particular paper, for forming at least one rod.

7. The production line according to any one of claims 1 to 5, wherein the wrapping device (33) of the assembling unit (6) comprises a rolling unit (34) through which the segments (3, 3a), made up of groups, are wrapped in a sheet of wrapping material, in particular paper, during a rolling motion of the segments themselves about their longitudinal axis (X).

8. A method for making rod-shaped articles of the tobacco industry, each of which is a multi-component article (2) which comprises a plurality of cylindrical segments (3, 3a) aligned with each other along the respective longitudinal axes (X), characterized in that it comprises the following steps:

- making at least some of the segments (3) forming each article (2) in the form of cylindrical capsules (3a), with a diameter equal to the diameter of all the segments (3) and containing inside them a filling material, in particular granules or fibres;

- feeding the segments (3, 3a) to an assembling unit (6), an inlet (I) of which is positioned and shaped to receive, in particular in an orderly succession, said capsules (3a);

- combining said segments (3, 3a) in groups in a modular combination section (30) of the assembling unit (6), in which each module (31) is equipped with a plurality of drums (32) for feeding the segments (3, 3a) in a direction transversal to their longitudinal axis (X), and in which at least two adjacent modules (31) combine the segments (3, 3a) by means of two respective drums (32) operatively coupled to each other; and

- wrapping a wrapping material around the combination of segments (3, 3a) in a wrapping section (33) of the assembling unit.

9. The method according to claim 8, wherein the step of feeding the segments (3, 3a) to the assembling unit (6) is achieved using respective feed units (5, 5a), which are independent of each other.

10. The method according to claim 8 or 9, wherein the step of feeding the capsules (3a) to the assembling unit (6) comprises transferring in sequence the capsules (3a) in an ordered succession from a pickup station (U), positioned at the outlet of a unit (7) for making the capsules, and a delivery station (I), located at the infeed of the assembling unit (6).

11. The method according to claim 10, wherein the transfer of the capsules (3a) comprises picking up the capsules (3a) from a first path, along which the capsules (3a) advance in a direction transversal to their longitudinal axis (X), and delivering the capsules (3a) to a second path, along which the capsules (3a) advance in a direction transversal to their longitudinal axis (X).

12. The method according to claim 10, wherein the transfer of the capsules (3a) comprises picking up the capsules (3a) from a first path, along which the capsules (3a) advance in a direction transversal to their longitudinal axis (X), and delivering the capsules (3a) to a second path, along which the capsules (3a) advance in the direction of their longitudinal axis (X).

13. The method according to any one of claims 8 to 12, wherein the step of wrapping a wrapping material around the combination of segments (3, 3a) is performed in a forming beam along which the segments (3, 3a), made up of groups, advance aligned with one another along the respective longitudinal axes (X) and wrapped during their advance by a continuous web of wrapping material, in particular paper, for forming at least one rod.

14. The method according to any one of claims 8 to 12, wherein the step of wrapping a wrapping material around the combination of segments (3, 3a) is performed in a rolling unit (34) through which the segments (3, 3a), made up of groups, are wrapped in a sheet of wrapping material, in particular paper, during a rolling motion of the segments (3, 3a) about their longitudinal axis (X).

Drawing